Abstract
Aiming at the shortcomings of the traditional permanent magnet governor air gap speed regulation, a sleeve-type electromagnetic hybrid governor is proposed by controlling the current instead of adjusting the air gap, the structural characteristics and working principle of the speed regulation model are introduced, and the electromagnetic torque mathematical expression is derived based on the equivalent magnetic circuit method, and the key parameters affecting the transmission performance of the governor are obtained, and the simulation model of the sleeve electromagnetic hybrid governor is established by using the finite element analysis method to analyze the electromagnetic field change law in the governor under the transient field. The change curve of air gap magnetic inductance intensity under different currents was obtained, and the influence of speed difference under different currents on the output torque was revealed, and finally, an experimental platform was built for testing, and the maximum error of torque simulation and the test was obtained by analyzing the results to verify the accuracy of the simulation method, on this basis, two structural schemes were proposed to improve the amplitude of the torque regulation of the governor by the current, under the structure of scheme 1, the adjustment amplitude of the torque increased from 35% of the original structure to 96%, and the improvement effect was ideal. Its laws and conclusions can provide a reference for the further design and optimization of sleeve electromagnetic hybrid governor.
Keywords
Introduction
The permanent magnet eddy current speed regulator is a novel speed-regulating magnetic coupling technology, which has advantages such as high reliability, low maintenance, large allowable misalignment, and no harmonic pollution [1–4]. It has good application prospects in power transmission in oil refining, coal, agriculture, mining machinery and other industries [5–8]. Based on the above advantages of the permanent magnet eddy current speed regulator, more and more scholars at home and abroad have begun to study it. Wang Shuai designed a disc-type permanent magnet eddy current coupling with power transmission and speed regulation functions. A calculation model for transferring torque and eddy current loss in the permanent magnet eddy current coupling was constructed, and the influence of leakage magnetic flux on magnetic induction intensity was analyzed [9]. Sun Zhongsheng et al. studied the magnetic field and mechanical characteristics of the cylinder permanent magnet governor and obtained the magnetic field and eddy current distribution of the governor, and the change curve of output power and torque with slip rate and meshing area [10]. Mohammadi et al. used the equivalent magnetic circuit method to derive the magnetic density formula and torque formula for the axial magnetized magnetic coupling and verified the correctness of the theoretical calculation by using a three-dimensional finite element simulation [11]. Lubin et al. used the vector magnetic potential method to neglect the magnetic field induced by the copper layer’s induction eddy currents. They obtained the torque of the coupling at lower slip rates and carried out an optimization analysis of various parameters to obtain the optimal structural scheme [12]. Yang Chaojun et al. used the magnetic circuit model of the coupling to analyze the torque and speed regulation relationship of the cylindrical asynchronous magnetic coupling, combined with the three-dimensional correction coefficient of the actual speed regulation process and derived the relationship between the meshing length of the internal and external rotor of the coupler and the slip rate when the speed regulation of different load modes was derived, and the accuracy of the relationship was verified by simulation and experiments [13].
The traditional magnetic governor is a rotor system composed of a stator and a rotor and a moving rotor, and the stator and rotor are mainly made of magnetic materials, and its structure usually has two configurations: disc type and sleeve type. Its speed regulation method is to change the size of electromagnetic torque by changing the air gap or meshing area between the main and slave rotors, to achieve speed regulation. However, whether by adjusting the air gap or adjusting the meshing area, the speed regulation accuracy and speed regulation range are relatively limited with the support of the mechanical adjustment mechanism. In addition, the traditional magnetic governor has a single-speed regulation method and requires a more complex adjustment device.
This paper proposes a sleeve-type electromagnetic hybrid governor to solve the above problems. The governor replaces the traditional mechanical adjustment mechanism by adjusting the size of the current in the winding, to achieve more convenient and high-precision speed regulation and effectively solve the shortcomings of the traditional magnetic governor. To study the speed regulation characteristics of sleeve electromagnetic hybrid governor, this paper derives the mathematical expression of electromagnetic torque based on the equivalent magnetic circuit method and explores the key parameters affecting the transmission performance of the governor. At the same time, the finite element method was used to analyze the electromagnetic field change law of the governor, and the influence of different currents and speed differences on the output torque was analyzed. Finally, we trial-produced the prototype and built an experimental platform for simulation experimental verification, based on which the speed regulation model is improved, which provides a reference for the further design optimization of the sleeve electromagnetic hybrid governor.
Highlights of this paper are as follows:
A sleeve-type electromagnetic hybrid governor is proposed, and the mathematical expression of electromagnetic torque is derived; Using the finite element method, the key parameters affecting the transmission performance of the sleeve electromagnetic hybrid governor were explored; The prototype was trial-produced and experimentally verified, and the governor model was further optimized based on verifying the accuracy of the simulation.
Model analysis and calculation
Structure and working principle
Figure 1 shows a model of a cartridge electromagnetic hybrid governor. The governor contains two parts, the active rotor, and the driven rotor, the active rotor is composed of a conductor barrel and a conductor yoke iron, which is connected to the input shaft; The driven rotor is composed of a mounting cylinder, a permanent magnet, a coil, and a conductive slip ring, and is connected to the output shaft, separated by an air gap between the two rotors, and its basic structural parameters are shown in Table 1.
Start the drive motor, and the input shaft drives the movement of the active rotor and drives the entire governor to rotate so that the conductor barrel does the movement of cutting magnetic inductance lines in the magnetic field. According to Faraday’s law of electromagnetic induction [14], when the magnetic field lines pass through the conductor barrel, the movement of the conductor barrel causes the magnetic flux through the conductor barrel to change, and the conductor cylinder generates induced eddy currents and further generates a magnetic field, which hinders the change of the magnetic field of the original same magnetic pole and attracts the opposite pole permanent magnet, thereby driving the driven rotor to rotate. The speed of the permanent magnet can be changed by adjusting the strength of the magnetic field, and this method of speed regulation is called magnetoresistive speed regulation. Several permanent magnets are distributed on the driven rotor, the poles of adjacent magnets are arranged alternately with N–S poles, and energized coils are surrounded by radially magnetized permanent magnets. By changing the different energizing directions of the coil windings, different external magnetic fields can be added, and the superposition of the two magnetic fields can play the role of demagnetization, magnetism, or alternating magnetism, and the influence of the electromagnetic field on the magnetic field of the permanent magnet can be changed by changing the input current, and the magnetic flux density passing through the conductor barrel can be adjusted, and the magnitude of the induced eddy current can be changed, and then the electromagnetic torque of the governor can be adjusted to achieve the purpose of speed regulation.

Model diagram of the sleeve-type electromagnetic hybrid governor.
Geometric parameters
To obtain the key parameters affecting the transmission performance of the governor, this paper uses the equivalent magnetic circuit method to calculate and derive its air gap magnetic flux and electromagnetic torque, to facilitate the analysis of the magnetic circuit of the sleeve governor, the original model is unfolded along the circumferential direction into a planar model, as shown in Fig. 3, the magnetic circuit of the governor has divided into the main magnetic circuit I, the leakage magnetic circuit II between adjacent magnets and the side leakage magnetic circuit III of a single permanent magnet.

Circumferential expansion diagram.

Equivalent magnetic circuit diagram of the governor.
According to the equivalent magnetic circuit method, the equivalent magnetic circuit diagram of the governor can be obtained, as shown in Fig. 4, wherein, R 0, R 1, R 2, R 3, R 4, R L are permanent magnet reluctance, air gap reluctance, copper conductor reluctance, outer yoke ferroresistive, inner yoke ferroresistive, and leakage reluctance. 𝛷0 is the total magnetic flux of the loop, 𝛷2 is the leakage flux of the loop [15], 𝛷1 is the main magnetic flux of the loop, F m , F n is the magnetomotive force of the permanent magnet magnetic field magnet, and the magnetomotive force of the energized coil-induced magnetic field, respectively.
According to Kirchhoff’s law, the magnetic flux relationship and the magnetomotive force relationship in the equivalent magnetic circuit of the governor are:
The magnetomotive force of a single permanent magnet is:
The magnetomotive force of the magnetic field induced by the energized coil is:
The magnetic flux density is calculated as:
Thus, the static air gap magnetic flux density of the governor is:
The three-dimensional end effect of the governor cannot be ignored, and the coefficient correction under the three-dimensional end effect is carried out by Mohammadi [11] using the ohmic loss in the conductor layer to calculate the torque calculation formula of the governor:
It can be seen from the above that the slip between the main and slave rotors and the induced magnetic field generated by the energized coil have an important impact on the speed regulation performance of the governor, to analyze its influence on the electromagnetic torque change of the governor, these parameters are simulated and analyzed below.
Three-dimensional magnetic field simulation of the governor
The magnetic field of the hybrid governor is superimposed by the permanent magnetic field and the electromagnetic field, considering the complexity of its multi-field superposition, the three-dimensional finite element method is used to simulate it and analyze its internal magnetic field distribution under different solvers. The three-dimensional model size of the governor is shown in Table 1, and the material properties are assigned to the model, wherein: the permanent magnet adopts rubidium iron boron, the yoke iron adopts mild steel Q235, the conductor barrel and coil material use copper, the relative permeability is 1.0.
The important role of permanent magnets in the governor is to provide a stable magnetic field, and the accuracy of their magnetic parameters will directly affect the overall performance. However, due to uncontrollable factors in the manufacturing process, shape, and size, the actual magnetic parameters may deviate from the standard values to a certain extent, resulting in errors in the later simulation calculations and test results. To reduce the effect of this situation, we calibrated the measurement of the magnetic properties on the surface of the permanent magnets using a gaussmeter (model LZ-643, manufactured by Lianzhong) and updated the default values of the magnetic parameters in the corresponding simulation software. Finally, the specific magnetic parameter values of the permanent magnets in this sample category were confirmed to be B r = 1.08 Tesla, the relative permeability 𝜇 r = 1.09, and the coercivity H c = −880000 A/m.
After meshing and solver settings, the mesh size between the different elements can have a great impact on the results of the finite element method. To reduce the simulation error, we carry out irrelevant processing on the mesh, eliminate the calculation error caused by uneven meshing, reduce the computational complexity, and enable the finite element analysis to obtain reliable results in a reasonable time. Considering that the conductor cylinder will be affected by the skin effect during the simulation process, the mesh refinement of the inner wall of the conductor cylinder is carried out. The solver sets the solution time to 0.1 seconds and the solution step size to 0.01 seconds. Finally, the model is solved and post-processing analysis is carried out.
The three-dimensional simulation model of the governor is shown in Fig. 4, to simplify the problem analysis, the following assumptions are made:
The governor model is simplified to be composed of a permanent magnet, a permanent magnet mounting cylinder, an energized coil, a conductor cylinder, and a conductor yoke iron, according to the principle of relative motion, assuming that the driven rotor is stationary and the active rotor rotates relative to the driven rotor [16]; Ignoring the conductor cylinder displacement current effect, the permanent magnet is uniformly magnetized, and the materials of each part of the governor are isotropic; During the simulation process, the vibration and deformation of the actual movement of the part are not considered [17].
Figure 5 is the induction eddy current vector diagram of the governor, as shown in the figure, the induction eddy current of the governor is generated in the conductor barrel, and its form is several annular circuits, the center density of the induction vortex is low, the density of the adjacent vortex junction is high, up to 6.57 × 106 A/m2, the induction eddy current direction of the adjacent circuit is opposite, the number of circuits of the induced eddy current is the same as the number of permanent magnets. Figure 6 is the magnetic induction intensity cloud of the governor, it can be seen that the magnetic induction intensity between adjacent permanent magnets on the conductor barrel is the largest, the maximum is 0.25 T, and the peak number of magnetic induction intensity is consistent with the number of alternating permanent magnets.

Three-dimensional model of a sleeve-type electromagnetic hybrid governor.

Vector diagram of induced eddy current.

Magnetic induction intensity cloud.
For magnetic drives, the magnetic induction intensity in the air gap region reflects the coupling effect between the magnet’s magnetic field and the induced magnetic field. To analyze the superposition effect of the permanent magnet magnetic field and electromagnetic magnetic field, the magnetic induction intensity of the main and slave rotor clearance of the governor was post-processed and analyzed. As shown in Fig. 7, the air gap magnetic induction intensity trend is sinusoidal, and the sum of the number of peaks and troughs is equal to the number of permanent magnets. Due to the influence of the shape of the magnet, the gap between the conductor barrel and the magnet is small on both sides and large in the middle, so that the maximum peak point of the air gap fluctuates. Due to the spaced arrangement of energized coils in the simulation model, when the input current changes, the magnetic induction intensity of the trough in the figure changes significantly, and the changing trend is that with the increase of the input current, the radial magnetic induction intensity of the air gap region will also increase accordingly.

Air gap magnetic induction intensity of governor.
Figure 8 when the input speed of the governor is 1500 r/min and the slip rate is 15%, the torque under different currents changes the curve with time, as shown in the figure, when the current is constant, the increase of torque with time gradually increases, and finally tends to be stable. At the same time, the torque will increase with the increase of the current, and the larger the input current, the greater the torque.

Torque change over time at different currents.

Torque changes with current under different slips.
The input speed of the governor is 1500 r/min, under different slip rates, the relationship between input current and torque is shown in Fig. 9, as shown in the figure, when the slip is fixed, the input current gradually increases, and the maximum torque that the governor can transmit gradually increases. When the current is constant, the torque increases with the increase of the slippage, and gradually decreases after increasing to the peak, which is because with the increase of the speed, the change of the air gap magnetic field accelerates, and the average magnetic flux at the air gap decreases, resulting in a decrease in the average magnetic flux density of the vortex flu, so that the output torque decreases.
Test platform construction
To verify the accuracy of the simulation calculation, the speed regulation process of the electromagnetic hybrid governor is experimentally verified. Figure 10 shows the test platform and self-developed sleeve electromagnetic hybrid governor, including sleeve electromagnetic hybrid governor (self-developed), a drive motor (QW80BL007301000), torque sensor (DYN-200), DC power supply (SPS3010), brake (PB-5 Kg) and tension controller (KTC800A).
The test and test operation process is: the power supply is turned on, the motor inputs constant speed, so that the active rotor speed is constant, at this time the relative movement between the main and slave rotors of the governor occurs, the active rotor cuts the magnetic field lines to generate an induced magnetic field, to hinder the change of the permanent magnet magnetic field to generate torque, so that the driven rotor begins to rotate. The load is applied to the driven rotor of the governor through the magnetic powder brake, and the output torque and output power are changed by adjusting the current output of the DC power supply, and the output torque displayed by the torque sensor is recorded at different currents. The data flow diagram of the test platform is shown in Fig. 11.

Experimental prototype test platform.

Test platform data flow diagram.
When the input speed is 1500 r/min and the slip rate is 15%, the comparison results of the test and simulation are shown in Table 2, it can be seen that the maximum error of the simulation test is 6.6%, and the change law of the analog value and the test value is basically the same, and the torque gradually increases with the increase of the current. To avoid the influence of excessive wire temperature on the test, the control input current is below 5 A, which is within the safe ampacity of the wire. Under these conditions, the torque test value and the analog value change range are the same, both 35%.
The main reasons for the errors in the test and simulation are: first, the simulation does not consider the influence of the temperature rise caused by eddy current loss on the conductivity of the copper disc and the error caused by the simplification of the model; Second, there are unavoidable processing and assembly errors in the test; Third, in actual operation, the governor will be affected by stray losses and wind and friction losses. Although there are certain errors in simulation and experiments, the errors are still within the allowable range of engineering research, which can verify the reliability of the simulation method adopted in this paper.
Comparison of test and simulation results (225 r/min & 3 mm)
Comparison of test and simulation results (225 r/min & 3 mm)
The magnetic governor is to change the size of the electromagnetic torque between the main and slave rotor to achieve the purpose of speed regulation, improve the torque change amplitude of the hybrid governor, further expand the speed regulation range, and improve the speed regulation performance, this paper designs two structural improvement schemes, as shown in Fig. 12. The three-dimensional magnetic field simulation solution of these two schemes is carried out, and the size of the output torque of the governor under different input currents under the same slip rate is obtained, and the adjustment amplitude of the governor with the current under different structural schemes is obtained, and the speed regulation characteristics of the original model are compared.
The first scheme is to use coil windings to control the permanent magnets, that is, one or more sets of coil windings are added to each permanent magnet, and the number of coil turns in all coil windings is the same. To increase the modulation ability of the electromagnetic field to the air-gap magnetic field, we can make the input currents in the windings of adjacent coils go in opposite directions, which will form a reverse magnetic field that cancels out the magnetic field generated by the permanent magnet. The second scheme is to add an electromagnet core based on the first plan, that is, to add an electrical pure iron material with a thickness of about 3 mm to the departing air gap surface of the permanent magnet to enhance the influence of the induced magnetic field of the coil on the magnetic field of the permanent magnet. In this way, the strength and stability of the magnetic field can be further increased.
Both of these schemes can achieve better EM control, but they also have some differences. The first scheme is relatively simple, and only needs to add coil windings to the permanent magnet to achieve the purpose; Although the second scheme is more complicated, it can further enhance the strength and stability of the magnetic field, and it is possible to achieve better results. The specific choice of which scheme needs to be comprehensively considered in combination with the actual needs and engineering conditions.

Model diagram of schemes 1 (left) and 2 (right).
The results of the three different structural schemes are shown in Table 3, the torque of the three schemes relative to the torque without current, the adjustment amplitude is 32.3%, 96%, and 63.6%, respectively, for the torque adjustment amplitude, the torque adjustment amplitude of scheme 1 is the largest, the effect is the best, but the torque size is compared, the output torque of scheme 2 is the largest, and the torque adjustment amplitude of both schemes is better than the torque of the original model.
Comparison of simulation results (150 r/min & 3 mm)
A sleeve-type electromagnetic hybrid governor was developed, which can achieve the purpose of efficient speed regulation by controlling the current, and the equivalent magnetic circuit method is used to obtain the air gap magnetic flux density expression and the electromagnetic torque mathematical expression of the governor, and the key parameters affecting the performance of the governor are obtained, and they are analyzed. The finite element method is used to simulate and analyze the governor, and the influence of current and slip on the electromagnetic torque of the governor is obtained, and the self-developed governor is used for test verification. The simulation error is less than 10%, which verifies the reliability of the simulation method within the allowable range of engineering research. Two structural schemes are proposed to improve the torque adjustment amplitude of the governor, according to the simulation results, the torque adjustment amplitude of scheme 1 and scheme 2 reaches 96% and 63.6% respectively, which are better than the adjustment amplitude of the original model, which can effectively increase the speed regulation range of the governor and improve the performance of the governor.
Footnotes
Acknowledgements
The authors thank the Anhui University of Science and Technology for providing support for the publication of this research. (E-mail:
Conflicts of interest
The authors declare no conflicts of interest.
Data availability statement
The data that support the findings of this study are available from the corresponding author.
Funding
This research was funded by Anhui Provincial Natural Science Foundation (Grant No. 2008085QE218).
Author contribution
Conceptualization, G.C.; methodology, G.C., and D.S.; software, G.C, and D.S.; validation, D.S.; formal analysis, D.S; investigation, G.C.; resources, D.S.; data cu-ration, D.S.; writing—original draft preparation, D.S.; writing—review and editing, G.C. and D.S. All authors have read and agreed to the published version of the manuscript.
